Auto-injection device

ABSTRACT

The present disclosure relates to an autoinjector device for use in combination with a syringe, said syringe comprising a movable plunger; a needle; and a tubular needle shield. The claimed autoinjector device comprises: an elongated housing having a proximal and a distal end; a drive mechanism; a syringe holder in order to support the fragile syringe and to prevent damage to the syringe. The invention furthermore relates to a method for assembly of the autoinjector device according to the invention.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent application Ser. No. 16/871,897, filed May 11, 2020, which is a continuation of U.S. patent application Ser. No. 16/045,820, filed Jul. 26, 2018, which is a continuation of U.S. patent application Ser. No. 15/809,398 filed Nov. 10, 2017, which is continuation of U.S. patent application Ser. No. 15/065,670, filed Mar. 9, 2016, now U.S. Pat. No. 10,137,248, which is continuation of U.S. patent application Ser. No. 14/365,635, filed Jun. 15, 2014, now U.S. Pat. No. 9,867,940, which is a U.S. National Phase Application pursuant to 35 U.S.C. § 371 of International Application No. PCT/SE2012/051365 filed Dec. 10, 2012, which claims priority to U.S. Provisional Patent Application No. 61/570,921 filed Dec. 15, 2011. The entire disclosure contents of these applications are herewith incorporated by reference into the present application.

FIELD OF DISCLSOURE

The present invention relates to an auto injection device for use in combination with a syringe, and a method for assembling said syringe in the autoinjector device.

BACKGROUND

Different types of autoinjectors are frequently used in order to facilitate administration of drugs to patients. When the proximal end of the autoinjector is correctly positioned against the intended area of the skin of the patient, an activation means on the autoinjector is pressed in order to activate the autoinjector. When activated, a needle rapidly punctuates the skin and the drug is delivered via the needle automatically.

There are two different categories of the autoinjectors on the market today. The first one uses custom designed medicament chambers, examples of these are described in WO2003/099358 and WO01/93926, while the second category uses standard pre-filled syringes. There are several advantages directed to the use of standard pre-filled syringes, for example the syringes have already been tested and approved in accordance with present regulations, which saves time and reduces the overall costs for the autoinjector. The present invention is directed to disposable autoinjectors used in combination with standard pre-filled syringes.

Since the autoinjectors are often used for self-administration of a drug to, the punctuation of the patients skin and the delivery of the drug via the needle are preferably performed rapidly which requires that a significant force is applied to the syringe by the drive mechanism. However, syringes are fragile and when the force of the drive mechanism is applied, there is a significant risk that the fragile syringe breaks.

In WO2007/083115 an autoinjector comprising a syringe support device intended to be arranged around the syringe and support the syringe at its front is disclosed. The support device reduces the risk of damage to the syringe but there is till a significant risk that the fragile syringe is damaged when a large force from the drive mechanism is applied upon activation of the autoinjector.

There is consequently still a need for an improved autoinjector device that further reduces the risk of damage to the syringe.

SUMMARY

The present invention, defined in the appended claims, provides an autoinjector device that fulfills the needs defined above.

The autoinjector device of the present invention is elongated along a longitudinal axis A and has a proximal end and an opposing distal end and comprises

-   -   a syringe having a substantially circular cross section having         an outer diameter, said syringe having a proximal end comprising         a neck and a distal end provided with a from the outer periphery         of the container radially extending flange; said syringe further         comprising a movable plunger, a needle and a tubular needle         shield having a outer diameter which is larger than the outer         diameter of the syringe,     -   an elongated autoinjector housing comprising a space for said         syringe;     -   a driving mechanism arranged in the distal end of the housing in         order to, when the autoinjector is activated, apply a force on         the movable plunger;     -   a syringe holder having a syringe holder wall with a         substantially tubular shape, said holder wall having:     -   an open distal end provided with a distal supporting collar         arranged around the outer periphery of said syringe holder wall         to support said syringe by the radially extending flange,     -   an open proximal end provided with a proximal supporting collar         arranged around the inner periphery of said syringe holder wall         to support said syringe neck, and     -   a slot extending from said open proximal end in the distal         direction resulting in a C-shaped cross sectional shape of the         syringe holder wall in the proximal end.

According to one aspect of the invention, the holder wall has a longitudinal length between the proximal supporting collar and the a distal supporting collar corresponding to the length of the syringe such that the a distal supporting collar of said syringe holder wall supports said radially extending flange of said syringe and said proximal supporting collar supports said neck of said syringe simultaneously when a force is applied on the movable plunger.

According to a further aspect of the invention, the proximal supporting collar has a inner diameter which is lesser than the outer diameter of the syringe and

According to another aspect of the invention, the proximal supporting collar has a inner diameter which is lesser than the outer diameter of the tubular needle covering shield.

According to a further aspect of the invention the proximal supporting collar is capable of flexing radially outward for allowing the the tubular needle shield to pass through when the syringe is longitudinally mounted in relation to the longitudinal axis (A) within the syringe holder.

The claimed invention fulfills the needs defined above since the syringe holder according to the invention provides support for the syringe along the entire length of the syringe. Furthermore the distal end of the syringe holder, due to the corresponding length of the syringe holder, will be in contact with the radially extending flange at the distal end of the syringe and support the flange when the force from the drive mechanism is applied. Since the syringe is supported both at the proximal end by the collar in contact with the neck and at the distal end by the flat surface in contact with the flange of the syringe, the risk that the syringe is damaged when a drive force is applied by the drive mechanism is reduced considerably.

A further advantage with the claimed injector device is that the C-shaped proximal end of the syringe holder facilitates the fitting of the syringe in the holder since the C-shaped cross section makes it possible for the proximal end of the syringe holder to flex and thereby allow the tubular needle shield, even though it has a diameter exceeding the inner diameter of the collar, to be moved past the collar. Once the syringe is fitted in the syringe holder the C-shaped collar will provide the desired support around almost the entire syringe neck which is favourable since the load on the syringe neck will be distributed over a larger area and the risk of damage to the syringe is reduced considerably.

In one embodiment of the invention, the autoinjector device comprises guiding means to control the movement of the syringe holder within the autoinjector housing when the syringe holder is longitudinally mounted in relation to the longitudinal axis (A) within the autoinjector housing. This is a favourable embodiment of the autoinjector device since the guiding means will assist during the preparation of the autoinjector device. The syringe is first fitted in the syringe holder by introduction of the proximal end of the syringe into the syringe holder via the distal end of the syringe holder and then moved in the proximal direction of the autoinjector device to the intended position within the proximal housing section during assistance by the guiding means that facilitates the mounting of the syringe and the syringe holder in the housing.

In one embodiment of the invention, the guiding means comprises protrusions arranged along the outer periphery of the syringe holder wall and corresponding grooves arranged along the inner periphery of the autoinjector housing. This embodiment of the guiding means provides satisfying guiding during the preparation of the autoinjector device.

One embodiment of the invention comprises corresponding openings or windows in the autoinjector housing and the syringe holder which make it possible to easily verify that the syringe is correctly fitted in relation to the syringe holder and the antoinjector housing.

In one embodiment of the invention, the syringe holder comprises locking means that secures the syringe holder in relation to the autoinjector housing when the syringe holder is longitudinally mounted in relation to the longitudinal axis (A) within the autoinjector housing.

In one embodiment of the invention, the outer periphery of the proximal end of the syringe holder is radially supported by a contact surface on the inside surface of the autoinjector housing when the syringe holder is in a proximal position within the autoinjector housing. This embodiment is favourable since the contact surface of the autoinjector housing will prevent the proximal end of the syringe holder wall from flexing radially outwards, which ensures that the syringe remains in the intended position in the syringe holder when the drive force is applied by the drive mechanism.

The different embodiments described above could of course be combined and modified in different ways without departing from the scope of the invention that is defined by the claims. Further details of the invention will be described in the detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

One embodiment of the present invention is illustrated in the appended figures, said figures disclosing:

FIG. 1 illustrates a perspective view of a syringe assembled in a syringe holder.

FIG. 2 illustrates a perspective view of a syringe holder.

FIGS. 3a, 3b and 3c illustrate exploded views of the autoinjector device at different steps during the assembly of the autoinjector device.

DETAILED DESCRIPTION

In FIGS. 3a to 3c , selected components of an autinjector device 10 according to the invention are illustrated. The autoinjector device 10, elongated along a longitudinal axis A, is intended for self-administration of drugs and has a proximal end 11 and an opposing distal end 12.

The autoinjector device comprises an autoinjector housing divided into a proximal housing section 13 and distal housing section 14 in order to make the space defined inside the housing accessible for assembly of the different components of the autoinjector.

The autoinjector housing has the shape of a tube. The autoinjector housing is intended to house a pre-filled syringe 30 within a syringe holder 40. A drive mechanism (not shown) is also arranged within the housing. The drive mechanism is arranged to apply a proximally directed drive force to a movable plunger in the syringe in order to expel the drug through a needle(not shown).

The drive mechanism is not illustrated in detail in the drawings but different types of drive mechanisms are available. The drive mechanism may comprise a pre-tensioned spring which upon activation applies a pre-determined pressure via plunger rod (not shown) to the movable plunger arranged in a distal end of the syringe.

The autoinjector is intended for use in combination with a standard pre-filled syringe 30. The syringe 30, assembled in the syringe holder 40 illustrated in perspective in FIG. 2, has a substantially circular cross section having an outer diameter. The syringe is normally made of glass in order to ensure a reliable and hygenic storing of the drug in the syringe 30. At a proximal end of the syringe 30, the outer diameter is reduced and shaped like a neck 32 at which a needle (not shown) and needle shield 34 are attached before delivery of the syringe. In order to ensure that the needle remains sterilized before use, the needle is protected by the needle shield 34 having a substantially circular cross section and having an outer diameter which is larger than the outer diameter of the elongated syringe. The tubular needle shield 34 may be a so-called Rigid Needle Shield (RNS). Further, the tubular needle shield 34 encloses the needle and is removably fastened to the syringe 30 at the neck 32. The distal end of the tube-shaped syringe 30 is arranged with a radially extending flange 35. The syringe 30 furthermore comprises a movable plunger arranged in the distal end of the syringe 30 to seal the syringe 30 and ensure that the pre-filled drug of the syringe remains in the syringe 30. The movable plunger is preferably made of a rubber material in order to achieve a seal between the inner periphery of the syringe 30 and the plunger.

The syringe 30 is secured in the autoinjector housing by a syringe holder 40 that is described in more detail below. The syringe holder 40 is arranged in the proximal housing section in order to support and maintain the syringe 30 in a pre-determined position in relation to the syringe holder and the autoinjector housing. During assembly of the autoinjector, the syringe 30 is first inserted in the syringe holder 40, which is then moved in the proximal direction of the autoinjector device 10 to a forward position where the syringe holder 40 is secured in the proximal housing section. The movement of the syringe holder in the proximal housing section is facilitated by guiding means 41 consisting of corresponding longitudinal protrusions 42 along the outer periphery of the syringe holder 40 and longitudinal recesses along the inner periphery of the proximal housing section. Furthermore corresponding snap-fitting fastening means 43 are arranged on the syringe holder 40 and the proximal housing section in order to permanently secure the syringe holder in the desired proximal position within the proximal housing section.

The syringe holder 40 provides a reliable and effective support for the fragile syringe 30 and reduces the risk of damage to the syringe 30. One embodiment of the syringe holder 40 is illustrated in FIG. 2 in a perspective view, where it is separated from the other components of the autoinjector device. The syringe holder 40 has a tubularly shaped holder wall 44 with a proximal end 45 and a distal end 46. The proximal end 45 of the syringe holder is open but provided with a proximal supporting collar 47 arranged around the inner periphery of said syringe holder wall in order to support said syringe neck 32 in the proximal longitudinal direction. Further, the proximal supporting collar 47 has a inner diameter which is lesser than the outer diameter of the elongated syringe and thus also lesser than the outer diameter of the tubular needle shield. A slot 48 extends from said open proximal end in the distal direction resulting in a C-shaped cross sectional shape of the syringe holder wall in the proximal end. The C-shaped holder wall in the proximal end 45 is able to flex radially outward which is essential in order to fit the syringe 30 in the syringe holder 40 since the tubular needle shield 34 has an outer diameter exceeding the inner diameter of the opening in the proximal supporting collar 47. This means that the syringe 30 may be fitted in the syringe holder 40 from the distal end 46 of the syringe holder. The syringe 30 is then moved in the proximal direction within the syringe holder 40. When the tubular needle covering shield 34 reaches the proximal supporting collar 47, the C-shaped holder wall will flex radially outward and thereby make it possible to move the syringe 30 further until the neck 32 of the syringe 30 is in contact with the collar 47, i.e the desired position of the syringe 30 within the syringe holder 40. In this position the needle shield 34 has completely passed the supporting collar 47, allowing the C-shaped holder wall to flex back, radially inward, behind the needle shield, such that the collar supports the syringe at the neck 32.

The syringe holder 40 furthermore comprises a distal supporting collar 49 arranged around the outer periphery of said syringe holder wall 44 and has a longitudinal length between the proximal supporting collar 47 and a distal supporting collar 49 that corresponds to the length of the syringe 30 so that the distal supporting collar 49 of said syringe holder wall, when the syringe 30 is fitted in the desired position within the syringe holder 40, is in contact with the proximal side of the radially extending flange 35 of the syringe 30 and provides further support for the fragile syringe 30 within the syringe holder 40 at the same time as the proximal supporting collar 47 supports the neck 32 of said syringe 30. Thereby the risk of damage to the syringe 30 is reduced significantly. The syringe holder 40 furthermore comprises guiding means that facilitates its movement in the longitudinal direction of the autoinjector device and locking means for securing the syringe holder in the proximal housing section before assembly of the syringe in the syringe holder 40.

The proximal housing section is furthermore provided with a window 15, or opening, corresponding to the slot 48 in the syringe holder 40 when the syringe holder 40 is fitted in the intended position in the proximal housing section in order to make the syringe 30, and the drug in the syringe, visible from the outside of the autoinjector housing and possible for the patient to verify that the autoinjector device is correctly assembled and ready for use.

Three different assembly steps of the autoinjector device are schematically illustrated in FIGS. 3a-3c . In FIG. 3a , the proximal housing section and the syringe holder 40 are illustrated without the syringe 30 fitted in the syringe holder 40. The syringe holder 40 is movably arranged in the proximal housing section between a distal position and a proximal position. Prior to fitting the syringe in the syringe holder the syringe holder is arranged in the distal position ready for assembly.

The assembly of the autoinjector device 10 is initiated by fitting the syringe 30 in the syringe holder 40 by inserting the proximal end of the syringe in the distal end of the syringe holder 40 and pushing the syringe in the proximal direction until the neck 32 of the syringe 30 is in contact with the collar 47 in the proximal end of the syringe holder40, where the collar has a plurality of radially inward directed shoulders 47 a, illustrated in FIG. 3b . The syringe 30 and the syringe holder 40 are then moved simultaneously in the proximal direction to the proximal position in the proximal housing section. In the proximal position, the outer periphery of the proximal end of the syringe holder 40 will be surrounded by support surfaces 16 on the inside surface of the proximal housing section. The cross sectional shape of the support surfaces correspond to the outer periphery of the syringe holder in order to provided a rigid support and prevent the C-shaped wall of the proximal end from flexing radially outwards in order to secure the syringe 30 in the syringe holder 40 and the autoinjector device 10, illustrated in FIG. 3c . Finally, the autoinjector housing is closed around the syringe 30 by fitting the distal housing section to the proximal housing section.

The assembly method of the present invention accordingly comprises the steps:

-   -   a). Inserting the proximal end of the syringe 30 in the distal         end of the syringe holder 40;     -   b). Moving the syringe 30 towards the proximal end of the         syringe holder until the neck 32 of the syringe 30 is in contact         with the proximal supporting collar 47 and the radially         extending flange 35 of the syringe 30 in contact with the distal         supporting collar 49 of the syringe holder 40;     -   c). Moving the syringe holder 40 and the syringe 30         simultaneously towards the proximal end of the autoinjector         device 10.

The different embodiments described above could be combined in different ways and modified further without departing from the scope of the invention that is defined by the claims. 

1-10. (canceled)
 11. A subassembly for use in fabricating a medical delivery device, wherein the subassembly comprises: a first axial configuration and a second axial configuration; a housing having a longitudinal axis and a support surface located on an inside surface of the housing; a syringe holder partially inserted into a distal end of the housing when the subassembly is in the first axial configuration; and a syringe having a needle shield affixed to the proximal end of the syringe adjacent to a neck portion of the syringe, where the needle shield has an outer diameter; wherein the syringe holder further comprises an open proximal end having radially inward directed shoulders arranged around an inner periphery of the open proximal end, wherein the radially inward directed shoulders define a first diameter and a second diameter, where the first diameter is less than the second diameter, wherein the first diameter temporarily changes to the second diameter when subassembly is in the first axial configuration and the syringe is longitudinally inserted into the syringe holder so that the needle shield is pushed through the open proximal end until the neck of the syringe is supported by the radially inward directed shoulders causing the second diameter to change back to the first diameter, wherein the syringe holder is movably arranged in the housing such that when the subassembly is in the second axial configuration an outer surface of the syringe holder will abut the support surface to prevent the radially inward directed shoulders from flexing radially outward.
 12. The subassembly of claim 11, wherein the support surface is not abutting or in contact with the outer surface of the syringe holder when the subassembly is in the first axial configuration.
 13. The subassembly of claim 11, wherein the support surface comprises a plurality of surfaces that surround the outer surface of the syringe holder when the subassembly is in the second axial configuration.
 14. The subassembly of claim 13, wherein each of the surfaces has a cross-sectional shape that corresponds to the outer surface of the syringe holder
 15. The subassembly of claim 11, wherein the syringe holder has a distal supporting collar arranged around and in contact with the outer surface of the syringe holder.
 16. The subassembly of claim 15, wherein the distal supporting collar comprises a surface that is perpendicular to the longitudinal axis and configured to abut a proximal side of a radially extending flange of the syringe when the subassembly is in the first axial configuration and in the second axial configuration.
 17. The subassembly of claim 11 further comprising a protrusion for controlling movement of the syringe holder within the housing when the subassembly transitions from the first axial configuration to the second axial configuration.
 18. The subassembly of claim 17, wherein the protrusion comprises a plurality of protrusions along the outer surface of the syringe holder wall and the housing further comprises a plurality of corresponding grooves along an inner periphery of the housing.
 19. The subassembly of claim 11 further comprising a fastener for securing the syringe holder in relation to the housing when the subassembly is in the second axial configuration.
 20. The subassembly of claim 11, wherein the outer diameter of needle shield is larger than the first diameter.
 21. A method of assembling a subassembly of a medical delivery device, the method comprising the steps of: providing a housing having a longitudinal axis and a support surface located on an inside surface of the housing; partially inserting a syringe holder into the distal end of the housing, where the syringe holder has an open distal end and an open proximal end having radially inward directed shoulders arranged around an inner periphery of the open proximal end; providing a syringe having a needle shield affixed to the proximal end of the syringe adjacent to a neck portion of the syringe, where the needle shield has an outer diameter; forming a first axial configuration of the subassembly by inserting the proximal end of a syringe into the distal end of the syringe holder and moving the syringe axially relative to the syringe holder so that the needle shield is pushed through the open proximal end until the neck of the syringe is supported by the radially inward directed shoulders; forming a second axial configuration of the subassembly axially moving the syringe holder and the syringe proximally relative to the housing until the support surface abuts an outside surface of syringe holder so as to prevent the radially inward directed shoulders from flexing radially outward.
 22. The method of claim 21 further comprising contacting a flange of the syringe with a distal supporting collar of the syringe holder.
 23. The method of claim 21 further comprising moving both the syringe holder and the syringe simultaneously to form the second configuration of the subassembly. 